US11545302B2 - Mold for forming a radio frequency (RF) coil for a plasma processing apparatus - Google Patents
Mold for forming a radio frequency (RF) coil for a plasma processing apparatus Download PDFInfo
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- US11545302B2 US11545302B2 US16/752,446 US202016752446A US11545302B2 US 11545302 B2 US11545302 B2 US 11545302B2 US 202016752446 A US202016752446 A US 202016752446A US 11545302 B2 US11545302 B2 US 11545302B2
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C41/00—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor
- B29C41/34—Component parts, details or accessories; Auxiliary operations
- B29C41/38—Moulds, cores or other substrates
- B29C41/40—Cores
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
- B29C64/10—Processes of additive manufacturing
- B29C64/141—Processes of additive manufacturing using only solid materials
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y80/00—Products made by additive manufacturing
Definitions
- the present disclosure relates to radio frequency (RF) coils for use in a plasma processing apparatus.
- RF radio frequency
- the present disclosure provides various embodiments of molds and methods of forming an RF coil.
- Plasma processing apparatuses are used extensively in the fabrication of semiconductor devices and other electronic devices.
- a plasma is used to perform a process, such as etching, deposition, oxidation, sputtering, etc. so as to achieve a good reaction of a processing gas at a relatively low temperature.
- Conventional plasma processing apparatuses used for such purposes include, but are not limited to, capacitively coupled plasma (CCP) and inductively coupled plasma (ICP) apparatuses.
- plasmas are generated in a vacuum chamber and the means for generating the plasma are either located outside the chamber, or within a protective wall, to reduce the disturbance to the plasma potential when RF power is applied.
- a coil-shaped RF antenna may be positioned outside of a dielectric window formed within a wall of a processing chamber, which serves as a vacuum chamber for the generated plasma.
- a target substrate for example, a semiconductor wafer or a glass substrate is provided at a central region within the processing chamber.
- a processing gas is supplied into a processing space formed between the dielectric window and the substrate.
- a high frequency alternating current (AC) current is supplied to the coil-shaped RF antenna to induce an RF magnetic field, which is transmitted to the processing space within the chamber via the dielectric window.
- AC alternating current
- an inductive electric field is generated in an azimuth direction within the processing space to create an intense plasma.
- characteristics of the coil-shaped RF antenna may be altered to affect plasma density and repeatability. For example, varying the geometry of the coil will impact the plasma characteristics, based on varying features such as pitch, diameter, length, etc. (e.g., an increase in the pitch of the coil will change the plasma generation region, the plasma density, and the plasma uniformity).
- RF coil designs are typically sent to an outside vendor for fabrication via a manufacturing process, which includes a combination of hand bending and winding machinery.
- a manufacturing process which includes a combination of hand bending and winding machinery.
- fabricating an RF coil by hand is not very accurate, and often fails to achieve the tight tolerances demanded by the plasma process.
- the manufacturing process also tends to create uneven surfaces and warped geometries (e.g., deformed coil shapes), which may influence the near field behavior of the fabricated RF coil.
- the tight bend radius, coil concentricity and coil diameter are especially difficult to predict and may need to be adjusted throughout the design process. Even small deviations from concentricity, for example, can lead to non-uniformity, poor ignition behavior or anomalous discharge in the plasma process.
- many outside vendors have long lead times (e.g., about 4-6 weeks), which may significantly increase design time, especially when multiple iterations are needed to perfect the RF coil design.
- the disclosed mold may generally include a cylindrical inner core having a first helically shaped groove formed within an outer surface of the cylindrical inner core, and a two-piece compression sleeve having a second helically shaped groove formed within an inner surface of the two-piece compression sleeve.
- the two-piece compression sleeve When portions of the two-piece compression sleeve are attached together, the two-piece compression sleeve surrounds the cylindrical inner core and provide a compressive force to a conductor arranged within the first and second helically shaped grooves to fabricate the RF coil.
- a three-dimensional (3D) printing process may be used to fabricate each piece of the mold separately.
- 3D printing process to fabricate the mold disclosed herein, the present disclosure provides a method for fabricating an RF coil that is accurate, reproducible and more time/cost effective than conventional manufacturing processes.
- a mold for fabricating an RF coil for use within a plasma processing apparatus may generally include a cylindrical inner core and a two-piece compression sleeve.
- the cylindrical inner core may have a first helically shaped groove formed within an outer surface of the cylindrical inner core
- the two-piece compression sleeve may have a second helically shaped groove formed within an inner surface of the two-piece compression sleeve.
- the two-piece compression sleeve may be configured to surround the cylindrical inner core and provide a compressive force to a conductor arranged within the first and second helically shaped grooves to fabricate the RF coil.
- the conductor may include ferrous and non-ferrous metals, including for example, but not limited to, copper, aluminum or iron.
- the two-piece compression sleeve comprises a first portion and a second portion, which is removably attached to the first portion with one or more mechanical fasteners.
- the two-piece compression sleeve may comprise cope and drag parts that facilitate the negative shape of the part to be formed and the forming of the part to the desired shape. (e.g. the cavity diameter, outer coil diameter, and coil pitch, etc.)
- the mold may be shaped and dimensioned to form an RF coil for use within a plasma processing apparatus.
- the cylindrical inner core may have a height between 1 ⁇ 8 inch and 12 inches, a diameter between 1 ⁇ 8 inches and 24 inches, a number of turns between 1 and 100 and a pitch between 1 ⁇ 8 inch and 2 inches.
- the mold may be fabricated by using a three-dimensional (3D) printing process to separately fabricate each piece of the mold.
- the cylindrical inner core, the first portion of the two-piece compression sleeve and the second portion of the two-piece compression sleeve may each be fabricated, in some embodiments, by 3D printing a thermoplastic polymer material having a glass transition temperature above 100° C. and a compressive strength above 200 megapascal (MPa).
- other materials for example, but not limited to, carbon fiber-PC, carbon fiber, aluminum, stainless steel, Inconel, etc.
- the metals generally are stronger, and will provide a better, more consistent final shape.
- a method for forming an RF coil for use within a plasma processing apparatus may begin by using a 3D printing process to fabricate a mold comprising a cylindrical inner core and a two-piece compression sleeve, wherein a first helically shaped groove is formed within an outer surface of the cylindrical inner core and a second helically shaped groove is formed within an inner surface of the two-piece compression sleeve.
- the method may also include winding a portion of a conductor around the cylindrical inner core, so that the portion of the conductor is arranged within the first helically shaped groove.
- the method may further include applying the two-piece compression sleeve to the cylindrical inner core, so that the two-piece compression sleeve surrounds the cylindrical inner core and provides a compressive force to the portion of the conductor arranged within the first and second helically shaped grooves to form the RF coil.
- said using a 3D printing process to fabricate the mold may include using the 3D printing process to separately fabricate each piece of the mold.
- the cylindrical inner core, the first portion of the two-piece compression sleeve and the second portion of the two-piece compression sleeve may each be fabricated, in some embodiments, by 3D printing a thermoplastic polymer material having a glass transition temperature above 100° C. and a compressive strength above 200 MPa.
- other materials for example, but not limited to, carbon fiber-PC, carbon fiber, aluminum, stainless steel, Inconel, etc.
- the metals generally are stronger, and will provide a better, more consistent final shape.
- said using a 3D printing process to fabricate the mold may include using the 3D printing process to form the cylindrical inner core to have a height between 1 ⁇ 8 inch and 12 inches, a diameter between 1 ⁇ 8 inches and 24 inches, a number of turns between 1 and 100 and a pitch between 1 ⁇ 8 inch and 2 inches.
- said applying the two-piece compression sleeve may include applying a first portion of the two-piece compression sleeve to a first side of the cylindrical inner core, and applying a second portion of the two-piece compression sleeve to a second side of the cylindrical inner core, so that the second portion and the first portion surround the cylindrical inner core and the portion of the conductor.
- said applying the two-piece compression sleeve may also include attaching the first portion to the second portion with one or more mechanical fasteners to apply the compressive force to the portion of the conductor arranged within the first and second helically shaped grooves.
- the method may further include removing the one or more mechanical fasteners, removing the first and second portions of the two-piece compression sleeve from the cylindrical inner core and the RF coil, and removing the RF coil from the mold by rotating at least one of the RF coil or the cylindrical inner core with respect to each other.
- a method for forming an RF coil for use within a plasma processing apparatus may begin by fabricating a mold comprising a cylindrical inner core and a two-piece compression sleeve, so that a first helically shaped groove is formed within an outer surface of the cylindrical inner core and a second helically shaped groove is formed within an inner surface of the two-piece compression sleeve.
- the method may also include winding a portion of a conductor around the cylindrical inner core, so that the portion of the conductor is arranged within the first helically shaped groove, and applying the two-piece compression sleeve to the cylindrical inner core, so that the two-piece compression sleeve surrounds the cylindrical inner core and provides a compressive force to the portion of the conductor arranged within the first and second helically shaped grooves to form the RF coil.
- the method may further include removing the two-piece compression sleeve from the cylindrical inner core and the RF coil, and removing the RF coil from the mold by rotating at least one of the RF coil or the cylindrical inner core with respect to each other.
- said applying the two-piece compression sleeve may include applying a first portion of the two-piece compression sleeve to a first side of the cylindrical inner core, and applying a second portion of the two-piece compression sleeve to a second side of the cylindrical inner core, so that the second portion and the first portion surround the cylindrical inner core and the portion of the conductor.
- said applying the two-piece compression sleeve may further include attaching the first portion to the second portion with one or more mechanical fasteners to apply the compressive force to the portion of the conductor arranged within the first and second helically shaped grooves.
- said removing the two-piece compression sleeve may include removing the one or more mechanical fasteners, and removing the first and second portions of the two-piece compression sleeve from the cylindrical inner core and the RF coil.
- FIG. 1 is a perspective, three-dimensional view of a mold for fabricating a RF coil, according to one embodiment of the present disclosure
- FIG. 2 is a flowchart diagram illustrating one embodiment of a method for forming an RF coil, in accordance with the present disclosure
- FIG. 3 is a flowchart diagram illustrating another embodiment of a method for forming an RF coil, in accordance with the present disclosure.
- FIGS. 4 , 5 , 6 , 7 , 8 , 9 and 10 are perspective, three-dimensional views of the mold shown in FIG. 1 , illustrating how the mold shown in FIG. 1 may be used to perform the method steps shown in FIGS. 2 and 3 .
- the disclosed mold may generally include a cylindrical inner core having a first helically shaped groove formed within an outer surface of the cylindrical inner core, and a two-piece compression sleeve having a second helically shaped groove formed within an inner surface of the two-piece compression sleeve.
- the two-piece compression sleeve When portions of the two-piece compression sleeve are attached together, the two-piece compression sleeve surrounds the cylindrical inner core and provide a compressive force to a conductor arranged within the first and second helically shaped grooves to fabricate the RF coil.
- a compressive force to a conductor arranged within the first and second helically shaped grooves to fabricate the RF coil.
- a three-dimensional (3D) printing process may be used to fabricate each piece of the mold separately.
- 3D printing process to fabricate the mold disclosed herein, the present disclosure provides a method for fabricating an RF coil that is accurate, reproducible and more time/cost effective than conventional manufacturing processes.
- FIG. 1 illustrates one embodiment of a mold 10 that may be used to fabricate an RF coil for use within a plasma processing apparatus.
- the mold 10 may include a cylindrical inner core 12 and a two-piece compression sleeve comprised of a first portion 20 a and a second portion 20 b .
- the cylindrical inner core 12 may include a base plate 14 at one end thereof, and first helically shaped grooves 16 formed within an outer surface of the cylindrical inner core 12 .
- the two-piece compression sleeve may include second helically shaped grooves 22 formed within an inner surface of the two-piece compression sleeve and means for attaching (e.g., attachment guides 24 and holes 26 ) portions of the two-piece compression sleeve together.
- the two-piece compression sleeve surrounds the cylindrical inner core 12 and provides a compressive force to a conductor 30 arranged within the first helically shaped grooves 16 and the second helically shaped grooves 22 to fabricate the RF coil.
- the two-piece compression sleeve includes a first portion 20 a and a second portion 20 b , which can be attached to and removed from the first portion with the aid of one or more mechanical fasteners 28 .
- the first portion 20 a may be attached to the second portion 20 b (or vice versa) by inserting one or more mechanical fasteners 28 (e.g., bolts and washers) within the attachment guides 24 and holes 26 formed within the two-piece compression sleeve, as shown in FIG. 7 .
- the two-piece compression sleeve provides a compressive force to the conductor 30 to conform the conductor to the shape and dimensions desired for the RF coil.
- the one or more mechanical fasteners 28 may be removed from the attachment guides 24 and holes 26 , so that the first portion 20 a can be removed from the second portion 20 b (or vice versa), as shown in FIG. 8 .
- attachment guides 24 , holes 26 and mechanical fasteners 28 are illustrated and described herein for attaching the first portion 20 a and the second portion 20 b of the two-piece compression sleeve together
- alternative means of attachment could be used to provide the compressive force necessary to form the RF coil. For example, sandwiching the assembly in a vice to provide a stronger, more uniform compressive force would be one way, or using a mold type frame to allow the parts to be used in a hydraulic press could be used.
- the mold 10 may generally be designed to produce an RF coil having particular characteristics (e.g., shape, size, pitch, length, etc.). For example, many RF coil designs are driven by physics-based RF/electromagnetic (EM) simulations, which determine the best coil shape, size, pitch, length, etc. for a specific application. Once an RF coil design is selected for a particular application, characteristics of the RF coil design may be used to design and fabricate the mold 10 .
- characteristics of the RF coil design may be used to design and fabricate the mold 10 .
- RF coils used in plasma processing apparatuses are typically formed to have a height (H 1 ) between 1 ⁇ 8 inch and 12 inches, a diameter (D 1 ) between 1 ⁇ 8 inch and 24 inches, a number of turns between 1 and 100, and a pitch between 1 ⁇ 8 inch and 2 inches. Any one of these characteristics may be adjusted to alter the electric field generated by the RF coil and the plasma generated within the plasma processing apparatus. For example, the height of the RF coil and the diameter may be adjusted. On the other hand, the number of turns used within the RF coil, and/or the pitch between turns, may also be adjusted. Changing the size and shape of the coil will change the electric field and inductance of the coil, which in turn changes the plasma density.
- the inner core 12 of the mold 10 may be formed with a height (H 2 ) between 1 ⁇ 4 inch and 8 inches and a diameter (D 2 ) between 1 ⁇ 4 inch and 24 inches. As shown in FIG. 1 , the height (H 2 ) is measured between an upper surface of the base plate 14 and an uppermost surface of the cylindrical inner core 12 . The diameter (D 2 ) is measured across the uppermost surface of the cylindrical inner core 12 .
- the first helically shaped grooves 16 formed within the cylindrical inner core 12 and the second helically shaped grooves 22 formed within each portion of the two-piece compression sleeve may each include a number of turns between 1 and 100.
- the depth of the first helically shaped grooves 16 and depth of the second helically shaped grooves 22 may each be substantially equal to one-half of the diameter of the conductor 30 .
- Conductor 30 may generally be formed from substantially any electrically conductive material.
- conductor 30 may be a ferrous or non-ferrous metal, including but not limited to, copper, aluminum, or iron.
- the compressive force applied to the conductor 30 causes the conductor to conform to the shape and dimensions of the first helically shaped grooves 16 and second helically shaped grooves 22 .
- an RF coil is formed having a helically shaped coil portion 32 and two substantially straight end portions, straight end portion 34 and straight end portion 36 .
- the shape and dimensions of the helically shaped coil portion 32 are generally dependent on the characteristics of the mold 10 used to form the coil.
- the helically shaped coil portion 32 may be formed, so as to have a height (H 1 ) between 1 ⁇ 4 inch and 8 inches, a diameter (D1) between 1 inch and 24 inches, a number of turns between 1 and 100, and a pitch between 5 ⁇ 8 inch and 2 inches.
- the first portion 20 a and the second portion 20 b of the two-piece compression sleeve may include an additional groove 27 a and additional groove 27 b , respectively, formed within an abutment surface 29 a and abutment surface 29 b , respectively, to accommodate and/or support one of the substantially straight end portions (e.g., 34 ).
- the additional grooves may be omitted, for example, if the base plate 14 was removed and the substantially straight end portion 34 was made to extend in the opposite direction.
- the two-piece compression sleeve may include cope and drag parts that facilitate the negative shape of the part to be formed and the forming of the part to the desired shape. (e.g. the cavity diameter, outer coil diameter, and coil pitch, etc.).
- the compression sleeve prevents uneven surfaces and warped geometries (e.g., deformed coil shapes) in the RF coil when the compressive force is applied to the conductor 30 .
- RF coils are typically made by outside vendors, which fabricate the RF coils through a combination of handing, bending, and winding machinery.
- the manufacturing methods utilized by most outside vendors lack accuracy and tend to create uneven surfaces and warped geometries (e.g., deformed coil shapes), which may influence the near field behavior of the RF coil.
- many outside vendors have long lead times (e.g., about 4-6 weeks), which significantly increase design time, especially when multiple iterations are needed to perfect the RF coil design.
- the mold 10 shown in FIG. 1 is preferably formed using a three-dimensional (3D) printing process.
- 3D printing is an additive manufacturing process that uses Computer Aided Design (CAD) software to direct hardware to deposit material, layer upon layer, in precise geometric shapes, and can be used to make 3D objects quickly, accurately, and at low cost.
- CAD Computer Aided Design
- each piece of the mold 10 e.g., the cylindrical inner core 12 , the first portion 20 a and the second portion 20 b of the two-piece compression sleeve
- each piece of the mold 10 may be fabricated by instructing a 3D printer to deposit a thermoplastic polymer material, layer upon layer, until the cylindrical inner core 12 , the first portion 20 a and the second portion 20 b are formed to the desired specifications.
- a thermoplastic polymer material having a glass transition temperature (Tg) above 100° C. and a compressive strength above 200 MPa may be preferred in at least some embodiments.
- a carbon fiber polycarbonate material having a Tg of about 147° C. and a compressive strength of about 320 MPa may be used to form the cylindrical inner core 12 , the first portion 20 a and the second portion 20 b of the two-piece compression sleeve of the mold 10 .
- a mold 10 was initially constructed using polylactic acid or polylactide (PLA), which has a substantially lower Tg (about 55-60° C.) and compressive strength (about 94 MPa) than carbon fiber polycarbonate.
- PLA polylactic acid or polylactide
- the PLA mold deformed near the RF coil area, most likely due to heat generated during the coil formation process or the compressive force need to form the coil. It was subsequently found that by using a carbon fiber polycarbonate material instead of PLA, the mold was able to withstand higher compressive forces and temperatures, thereby avoiding the deformation suffered by the PLA mold.
- thermoplastic polymer materials may include a wide variety of materials, including but are not limited to, Kyron and MAX-XS.
- mold 10 may be alternatively formed by 3D printing metals such as, but not limited to, aluminum, stainless steel or Inconel.
- FIGS. 2 - 10 illustrate exemplary methods of forming an RF coil using the mold 10 shown in FIG. 1 and described above.
- FIGS. 2 and 3 are flowchart diagrams illustrating example embodiments of methods 100 and 200 that may be used to form an RF coil, in accordance with the present disclosure.
- FIGS. 4 - 10 illustrate how the mold 10 shown in FIG. 1 may be used to perform the method steps shown in FIGS. 2 and 3 .
- the mold 10 shown in FIG. 1 and the methods 100 and 200 shown in FIGS. 2 and 3 are use to form an RF coil for use within a plasma processing apparatus, it is noted that a similar mold and/or similar methods may be used to form RF coils for other uses and applications.
- FIGS. 4 - 10 are merely exemplary and additional methods may utilize the techniques described herein. Further, additional steps may be added to the methods shown in the FIGS. 4 - 10 as the steps described are not intended to be exclusive. Moreover, the order of the steps is not limited to the order shown in the figures as different orders may occur and/or various steps may be performed in combination or at the same time.
- FIG. 2 illustrates an exemplary method 100 of forming a RF coil for use within a plasma processing apparatus.
- the method 100 shown in FIG. 2 may begin (in step 110 ) by using a 3D printing process to fabricate a mold comprising a cylindrical inner core and a two-piece compression sleeve, wherein a first helically shaped groove is formed within an outer surface of the cylindrical inner core and a second helically shaped groove is formed within an inner surface of the two-piece compression sleeve.
- FIG. 1 illustrates one embodiment of a mold 10 that can be fabricated to include the above-mentioned structures using a 3D printing process.
- said using a 3D printing process to fabricate the mold includes using the 3D printing process to separately fabricate the cylindrical inner core 12 , a first portion 20 a of the two-piece compression sleeve and a second portion 20 b of the two-piece compression sleeve using a thermoplastic polymer material having a glass transition temperature above 100° C. and a compressive strength above 200 MPa.
- a variety of thermoplastic polymer materials may be used.
- said using a 3D printing process to fabricate the mold includes fabricating the cylindrical inner core 12 to have a height between 1 ⁇ 4 inch and 8 inches and a diameter 1 inch and 24 inches, and fabricating the first and second helically shaped grooves 16 / 22 to have a number of turns between 1 and 100 and a pitch between 5 ⁇ 8 inch and 2 inches.
- a mold 10 having such shapes and dimensions may be suitable for forming an RF coil for use in a plasma processing apparatus.
- a mold fabricated using a 3D printing process may be used to form an RF coil that is suitable for other uses and applications.
- step 120 method 100 includes winding a portion of a conductor around the cylindrical inner core, so that the portion of the conductor is arranged within the first helically shaped groove.
- a portion of conductor 30 e.g., a coil portion 32
- step 130 method 100 includes applying the two-piece compression sleeve to the cylindrical inner core, so that the two-piece compression sleeve surrounds the cylindrical inner core and provides a compressive force to the portion of the conductor arranged within the first and second helically shaped grooves to form the RF coil.
- said applying the two-piece compression sleeve may include applying a first portion 20 a of the two-piece compression sleeve to a first side of the cylindrical inner core (as shown in FIG. 5 ), and applying a second portion 20 b of the two-piece compression sleeve to a second side of the cylindrical inner core (as shown in FIG.
- said applying the two-piece compression sleeve may further include attaching the first portion 20 a to the second portion 20 b with one or more mechanical fasteners 28 to apply the compressive force to the portion of the conductor 30 arranged within the first and second helically shaped grooves (as shown in FIG. 7 ).
- method 100 may further include removing the one or more mechanical fasteners 28 (as shown in FIG. 8 ), removing the first portion 20 a and the second portion 20 b of the two-piece compression sleeve from the cylindrical inner core 12 and the RF coil (as shown in FIGS. 8 and 9 ), and removing the RF coil from the mold by rotating at least one of the RF coil or the cylindrical inner core 12 with respect to each other (as shown in FIG. 10 ).
- FIG. 3 illustrates an exemplary method 200 of forming an RF coil for use within a plasma processing apparatus.
- the method 200 shown in FIG. 3 may begin (in step 210 ) by fabricating a mold comprising a cylindrical inner core and a two-piece compression sleeve, so that a first helically shaped groove is formed within an outer surface of the cylindrical inner core and a second helically shaped groove is formed within an inner surface of the two-piece compression sleeve.
- the mold may be fabricated (in step 210 ) using a 3D printing process, as described above. It is noted, however, that method step 210 is not strictly limited to a 3D printing process and could be performed using other suitable processes.
- step 220 method 200 includes winding a portion of a conductor around the cylindrical inner core, so that the portion of the conductor is arranged within the first helically shaped groove.
- a portion of conductor 30 e.g., a coil portion 32
- step 230 method 200 includes applying the two-piece compression sleeve to the cylindrical inner core, so that the two-piece compression sleeve completely surrounds the cylindrical inner core and provides a compressive force to the portion of the conductor arranged within the first and second helically shaped grooves to form the RF coil.
- said applying the two-piece compression sleeve may include applying a first portion 20 a of the two-piece compression sleeve to a first side of the cylindrical inner core (as shown in FIG. 5 ), and applying a second portion 20 b of the two-piece compression sleeve to a second side of the cylindrical inner core (as shown in FIG.
- said applying the two-piece compression sleeve may further include attaching the first portion 20 a to the second portion 20 b with one or more mechanical fasteners 28 to apply the compressive force to the portion of the conductor 30 arranged within the first and second helically shaped grooves (as shown in FIG. 7 ).
- step 240 method 200 includes removing the two-piece compression sleeve from the cylindrical inner core and the RF coil.
- the two-piece compression sleeve may be removed from the cylindrical inner core 12 and the RF coil (in step 240 ) by removing the one or more mechanical fasteners 28 (as shown in FIG. 8 ) before removing the first portion 20 a and the second portion 20 b of the two-piece compression sleeve from the cylindrical inner core 12 and the RF coil (as shown in FIGS. 8 and 9 ).
- step 250 method 200 includes removing the RF coil from the mold by rotating at least one of the RF coil or the cylindrical inner core with respect to each other.
- the RF coil may be removed from the mold 10 (in step 250 ) by rotating the RF coil with respect to the cylindrical inner core 12 (or vice versa).
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Priority Applications (6)
Application Number | Priority Date | Filing Date | Title |
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US16/752,446 US11545302B2 (en) | 2020-01-24 | 2020-01-24 | Mold for forming a radio frequency (RF) coil for a plasma processing apparatus |
CN202080094513.7A CN114981915A (en) | 2020-01-24 | 2020-10-26 | Mold and method for forming a Radio Frequency (RF) coil for a plasma processing apparatus |
JP2022544684A JP7485886B2 (en) | 2020-01-24 | 2020-10-26 | Mold and method for forming radio frequency (RF) coils for plasma processing equipment - Patents.com |
PCT/US2020/057284 WO2021150281A1 (en) | 2020-01-24 | 2020-10-26 | Mold and method of forming a radio frequency (rf) coil for a plasma processing apparatus |
KR1020227028445A KR20220130740A (en) | 2020-01-24 | 2020-10-26 | Molds and Methods for Forming Radio Frequency (RF) Coils for Plasma Processing Devices |
TW110101403A TW202147375A (en) | 2020-01-24 | 2021-01-14 | Mold and method of forming a radio frequency (rf) coil for a plasma processing apparatus |
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US16/752,446 US11545302B2 (en) | 2020-01-24 | 2020-01-24 | Mold for forming a radio frequency (RF) coil for a plasma processing apparatus |
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US20210233706A1 US20210233706A1 (en) | 2021-07-29 |
US11545302B2 true US11545302B2 (en) | 2023-01-03 |
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JP (1) | JP7485886B2 (en) |
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- 2020-10-26 JP JP2022544684A patent/JP7485886B2/en active Active
- 2020-10-26 CN CN202080094513.7A patent/CN114981915A/en active Pending
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JP2023511192A (en) | 2023-03-16 |
US20210233706A1 (en) | 2021-07-29 |
CN114981915A (en) | 2022-08-30 |
KR20220130740A (en) | 2022-09-27 |
JP7485886B2 (en) | 2024-05-17 |
TW202147375A (en) | 2021-12-16 |
WO2021150281A1 (en) | 2021-07-29 |
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